IMPROVISED MUFFLER EXTENSION WITH MAGNESIUM

HYDROXIDE [MG(OH)2] AS A POTENTIAL CARBON MONOXIDE

(CO) AND HYDRO CARBON (HC) FILTER

ME 300
THESIS PROPOSAL

JOEMAR S. PEPITO
Student

GERALD JO C. DENOGA, PH.D.

Adviser

MASTER OF SCIENCE IN MECHANICAL ENGINEERING

SEP 2019

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Table of Contents

CHAPTER 1: INTRODUCTION ................................................................................................................... 3

1.1 Motivation......................................................................................................................................... 3
1.2 Background of the study ................................................................................................................... 3
1.2.1 Materials selection......................................................................................................................... 4
1.3 Statement of the problem ................................................................................................................ 5
1.4 Objectives.......................................................................................................................................... 5
1.4.1 Specific objectives are to ............................................................................................................... 6
1.5 Scope and limitations ........................................................................................................................ 6
CHAPTER 2: REVIEW OF RELATED LITERATURE ...................................................................................... 6
2.1 Introduction ...................................................................................................................................... 7
2.2 Carbon monoxide and hydrocarbon pollution.................................................................................. 7
2.3 Magnesium hydroxide ...................................................................................................................... 8
2.4 Magnesium hydroxide as emission control agent ............................................................................ 9
2.4.1 Selective catalytic reduction .......................................................................................................... 9
2.4.2 Double displacement reaction ....................................................................................................... 9
CHAPTER 3: METHODOLOGY ................................................................................................................ 10
3.1 Material preparation and fabrication ............................................................................................. 11
3.2 Magnesium hydroxide handling ..................................................................................................... 11
3.3 Experimentation and testing .......................................................................................................... 12
Timeline................................................................................................................................................. 17
References ............................................................................................................................................ 18

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CHAPTER 1: INTRODUCTION

1.1 Motivation

Earth has been suffering because of industrialization and human activities.

Humanity may have only a narrow window of time left, perhaps a decade or so, to

begin the long process of stabilizing greenhouse gas concentrations at a level that can

avert devastating and irreversible impacts from climate change.

The study is to be conducted to test the potential of improvised muffler

extension with magnesium hydroxide [Mg(OH)2] as carbon monoxide (CO) and

hydrocarbon (HC) filter and to determine the concentration of Mg(OH)2 which is the

most effective and efficient in filtering CO and HC. Magnesium hydroxide is abundant

source as inorganic compound and also naturally found as the mineral brucite with an

estimated price per ton of $190-$750 that is very low in price compared to the

commonly used precious metals (platinum $26.11 per gram, palladium $192.7 per

gram and rhodium $70 per gram) in catalytic converters used in vehicles in this modern

world.

1.2 Background of the study

Mufflers are installed within the exhaust system of most internal combustion

engines. The muffler is engineered as an acoustic device to reduce the loudness of

the sound pressure created by the engine by acoustic quieting. The noise of the

burning-hot exhaust gas exiting the engine at high velocity is abated by a series of

passages and chambers lined with roving fiberglass insulation and/or resonating

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chambers harmonically tuned to cause destructive interference, wherein opposite

sound waves cancel each other out [17].

Figure 1. A cutaway muffler showing the interior pipes and chambers.

1.2.1 Materials selection

The exhaust manifold of an automobile engine is always exposed to hot gases.

Cast iron has been in use for the production of exhaust manifolds traditionally. The

main characteristics required for the exhaust manifold material include thermal fatigue

strength required to withstand the high temperature exhaust gases, oxidation

resistance, good fabrication properties and low thermal capacity to enhance the

catalytic function. Ferritic stainless steel exhibit all these properties and offers big

weight reduction also. The developments in vacuum casting process has helped in the

fabrication of stainless steel manifold with section thickness of 2-5mm. Higher

demands in pollution control will rise the exhaust temperatures too and therefore,

ferritic stainless steel will be in major use for exhaust system manufacturing. Ferritic

stainless steel exhibits improves thermal fatigue characteristics when processed by

solid solution strengthening with molybdenum or niobium. This process also improves

the oxidation resistance and microstructural stability. Ferritic stainless steel also has

cost advantages because of the absence of nickel in its composition. Another variant

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called the austenite stainless steel is used where ferritic stainless steel is unsuitable.

Austenite stainless steel can enhance its properties when enough carbon is added to

it. But, the higher cost limits its usage compared to the ferritic variant [16].

1.3 Statement of the problem

Climate change caused by heavy concentrations of greenhouse gases is one

of the major problem the earth is currently facing in today’s world. Most of it was due

to industrialization and other human activities. The emission of carbon monoxide from

cars for example is one of top emission contributors. Thus, humankind performed

various studies and experiments to lessen carbon monoxide and hydrocarbon

emissions on the atmosphere.

Philippines is one of the rising industrial country, which makes it prone to heavy

carbon monoxide and hydrocarbon emissions. The currently and commonly used

emission control system are the catalytic converters. However, the materials used in

this type of emission control device are precious metals that are very expensive and

not abundant in nature. Thus, the researcher intend to mitigate this problem by using

magnesium hydroxide as filter for the said emissions and this will be mounted at the

exhaust manifold tailpipe of an internal combustion engine.

1.4 Objectives

The general objective of the study is to investigate the potential of magnesium

hydroxide as emission reduction agent that will filter carbon monoxide (CO) and

hydrocarbons (HC) for internal combustion gasoline engines.

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1.4.1 Specific objectives are to:

 Design and fabricate the muffler extension that uses Mg(OH)2 to filter CO and

HC in an internal combustion gasoline engine.

 Test the potential of Magnesium Hydroxide in filtering CO and HC in an internal

combustion gasoline engine.

 Determine what concentration will be the most effective and efficient in filtering

CO and HC when the gasoline engine runs at idle, half load and full load

condition.

 Evaluate and compare the filtering performance of improvised muffler extension

with magnesium hydroxide to the currently used catalytic converters.

1.5 Scope and limitations

The coverage of this study is limited only to internal combustion engines,

specifically gasoline engines. The muffler extension will be inserted to an exhaust

tailpipe only. The result of this study will prove the muffler extension’s importance to

our environment in the future.

CHAPTER 2: REVIEW OF RELATED LITERATURE

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2.1 Introduction

Air pollution can be caused by both anthropogenic and natural sources. Air

pollution is causing stratospheric ozone depletion which is recognized as a threat to

human health as well as to the earth’s ecosystem. Air pollution is defined as emission

of harmful gases like CO and NOx from the industrial chimneys, automobiles and

aircrafts. Worldwide air pollution is caused due to the emission of hydrocarbons,

nitrogen oxides, carbon monoxide and carbon dioxide. Emission of these gases takes

place mainly due to the incomplete combustion of fuel and air mixture [10]. When

people inhale CO, the toxic gas enters the bloodstream and blocks oxygen from being

absorbed into the body, which can damage tissues and result in death [1].

2.2 Carbon monoxide and hydrocarbon pollution

Carbon Monoxide (CO) is an odorless, colorless, flammable and highly toxic

gas formed when not enough oxygen is present during the combustion process to

convert carbon (C) to Carbon Dioxide (CO2) (Andrew, 2009) while hydrocarbon (HC)

is an organic compound consisting entirely of Hydrogen (H) and Carbon (C)

(Silberberg, 2004) that is an essential fuel which was not burned during combustion

process or which has escaped into the atmosphere through fuel evaporation. An

increase in the carbon monoxide (CO) emission is normally accompanied by an

increase in the hydrocarbon (HC) emission because of the lack of oxygen to

completely burn all of the fuel mixture [2].

Carbon monoxide is a poisonous gas that has no smell or taste. Breathing it in

can make you unwell, and it can kill if you're exposed to high levels. Every year there

are around 60 deaths from accidental carbon monoxide poisoning in England and

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Wales. After carbon monoxide is breathed in, it enters your bloodstream and mixes

with haemoglobin (the part of red blood cells that carry oxygen around your body) to

form carboxyhaemoglobin. When this happens, the blood is no longer able to carry

oxygen, and this lack of oxygen causes the body's cells and tissue to fail and die [12].

As cited by Reay (2011), carbon monoxide is a greenhouse gas that can lead

to the formation of the tropospheric greenhouse gas 'ozone'. Hydrocarbons also

contributes to the formation of tropospheric ozone [7]. Ozone is one of the main

greenhouse gas when it is in the lower atmosphere (tropospheric ozone) which is

thought to have caused around one-third of all direct greenhouse gases that induced

warming since the industrial revolution and act as air pollutant [3].

Hydrocarbons react in the presence of nitrogen oxides and sunlight to form

ground-level ozone, a major component of smog. Ozone irritates the eyes, damages

the lungs, and aggravates respiratory problems. It is our most widespread and

intractable urban air pollution problem. A number of exhaust hydrocarbons are also

toxic, with the potential to cause cancer [9].

2.3 Magnesium hydroxide

Magnesium hydroxide is the inorganic compound with the chemical formula

Mg(OH)₂. It occurs in nature as the mineral brucite. It is a white solid with low solubility

in water. Magnesium hydroxide is a common component of antacids, such as milk of

magnesia, as well as laxatives [14]. Magnesium Hydroxide is generally immediately

available in most volumes. High purity, submicron and nanopowder forms may be

considered. Hydroxide, the OH- anion composed of an oxygen atom bonded to a

hydrogen atom, is commonly present in nature and is one of the most widely studied

molecules in physical chemistry. Hydroxide compounds have diverse properties and

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uses, from base catalysis to detection of carbon dioxide [15]. Magnesium hydroxide is

safer non-toxic, non-corrosive, non-hazardous, safe to handle and more

environmentally friendly. In addition, it is of lower cost ($190-$750 per metric ton) and

of high supply availability in the market [18].

2.4 Magnesium hydroxide as emission control agent

2.4.1 Selective catalytic reduction

For power plants and industrial companies using Selective Catalytic Reduction

(SCR) systems to control backend boiler emissions, UtiliMag H, a high-purity

magnesium hydroxide slurry and UtiliMag 40, a high-purity magnesium oxide (MgO)

powder can be used to significantly reduce sulfur trioxide (SO3) generated by the boiler

and SCR unit as well as opacity emissions and acid plumes related to SO 3. UtiliMag

H can be added from the superheater section to the SCR outlet for SO 3 control or to

reduce opacity. UtiliMag H is also effective in neutralizing acidic solutions generated

from wet electrostatic precipitators (WESP) and SO2 from flue gas desulfurization

(FGD) scrubbers. UtiliMag 40 can be injected downstream of the SCR to the air heater

inlet for effective SO3 removal, corrosion control and opacity treatment. Backend

treatment with UtiliMag 40 can also reduce the formation of ammonium bisulfate in the

air heater, resulting in less frequent, easier cleanup and elimination of corrosion [11].

2.4.2 Double displacement reaction

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 A double displacement reaction, also known as a double replacement reaction

or metathesis, is a type of chemical reaction where two compounds react, and the

positive ions (cation) and the negative ions (anion) of the two reactants switch places,

forming two new compounds or products. Here, you can see the general form of a

double displacement reaction:

where; A & C are (positive ions) cations and B & D are (negative ions) anions [13].

Magnesium Hydroxide is used as smoke suppress agent (Japan Technology

Association, 2004). With this reason, magnesium hydroxide (Mg(OH)2) captures

carbon monoxide (CO) through double displacement of compounds and yields

Magnesium Bicarbonate Mg(HCO3)2 and two Carbon (C) atoms as by-products.

Hydrocarbons are also captured as Mg(OH)2 reacts with two HC (e.g. CH4 –

methane) and 8 Oxygen atoms through double displacement of compounds and yields

Mg(HCO3)2 and 4 H2O as byproducts.

CHAPTER 3: METHODOLOGY

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3.1 Material preparation and fabrication

The materials will be purchase locally. The fabrication of muffler extension will

be perform in a machine shop using ferritic stainless steel, metal tubes, oxygen,

acetylene, welding rod and welding machine. The dimensions of the muffler extension

will be identified as 150 millimeters in length and 125 millimeters in diameter with three

chambers. A highly skilled welder will do the work in order to produce a quality and

durable output. The device will be incorporated with locking device (bolts, screws,

threads and nuts). Also, in order to produce a good output, the device will undergo

machining and painting. Glass adhesive and a sheet of rubber will be use as sealing

to prevent exhaust flue gas from leaking.

3.2 Magnesium hydroxide handling

The powdered form magnesium hydroxide will be placed in a well-designed

holder inside the improvise muffler. The prototype have three compartments where

the magnesium hydroxide will be place (as shown in figure 5). The compartments

inside the muffler are properly design for the ease of operation and maintenance. It

will be made with a detachable component. Also, the exhaust gas flaws to the three

compartments as shown in figure 4.

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3.3 Experimentation and testing

The muffler will be inserted at the exhaust manifold tailpipe of a gasoline engine

through bolts and nuts as shown in figure 3. The experiment will be group into three

loading conditions namely; idling, half and full load. Each of the three loading

conditions will undergo seven sets with three trials each. The gas analyzer that reads

emissions like CO, HC and etc. will be placed at the model exhaust. The seven sets

will be categorize into the following treatments per compartment as follows:

First set:

Compartment 1 – 20 grams of magnesium hydroxide

Compartment 2 – 20 grams of magnesium hydroxide

Compartment 3 – 20 grams of magnesium hydroxide

Second set:

Compartment 1 – 25 grams of magnesium hydroxide

Compartment 2 – 25 grams of magnesium hydroxide

Compartment 3 – 25 grams of magnesium hydroxide

Third set:

Compartment 1 – 30 grams of magnesium hydroxide

Compartment 2 – 30 grams of magnesium hydroxide

Compartment 3 – 30 grams of magnesium hydroxide

Fourth set:

Compartment 1 – 35 grams of magnesium hydroxide

Compartment 2 – 35 grams of magnesium hydroxide

Compartment 3 – 35 grams of magnesium hydroxide

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Fifth set:

Compartment 1 – 40 grams of magnesium hydroxide

Compartment 2 – 40 grams of magnesium hydroxide

Compartment 3 – 40 grams of magnesium hydroxide

Sixth set:

Compartment 1 – 45 grams of magnesium hydroxide

Compartment 2 – 45 grams of magnesium hydroxide

Compartment 3 – 45 grams of magnesium hydroxide

Seventh set:

Compartment 1 – 50 grams of magnesium hydroxide

Compartment 2 – 50 grams of magnesium hydroxide

Compartment 3 – 50 grams of magnesium hydroxide

The data will be recorded and analyze. The set with the maximum possible

filtering capability that will able to filter carbon monoxide and hydrocarbons effectively

and efficiently for the three loading conditions will be used.

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Dimensions of the model

Figure 2

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Installing the muffler extension on the tailpipe

Figure 3

Path of Carbon Monoxide (CO) and Hydrocarbons (HC) from the tailpipe

Figure 4

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Portions where the filter, Magnesium Hydroxide [Mg(OH)2] will be placed.

Figure 5

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Timeline

Tasks Proposed Working Schedule of Tasks (by 15 days)

Aug Sept Oct Nov Dec Jan Feb Mar Apr May

Research
Thesis
proposal
preparation
Submission of
Drafts
Thesis
proposal
presentation
Gathering of
materials and
fabrication
Preliminary
machine
testing
Performance
test and
evaluation
Data analysis
Submission of
drafts (1st, 2nd,
3rd)
Final thesis
defense
Finalizing
manuscript
Submission of
the book

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References

[1] National Center for Environmental Health, 2006

[2] Mary B. Collins et al, The environment and environmental justice: Linking the biophysical and the
social using watershed boundaries

[3] Houston K and Reay DS (2011) The Impact of ICT on greenhouse gas emissions: How Green are
Virtual Worlds? Carbon Management 2(6), 629-643.

[4] Reay DS (2011) Climate change education: cutting emissions with a Swiss army knife. Greenhouse
Gas Measurement and Management, 1(3-4), 139-141.

[5] Warnatzsch E and Reay DS (2011) Cutting CO2 emissions from the US energy sector: meeting a 50%
target by 2030. Carbon Management, 2(1), 23-39.

[6] Galt H and Reay DS (2011) Corn ethanol and associated greenhouse gas emissions in the USA:
importance of the nitrous oxide emission factor. Carbon Management, 2(1), 13-22.

[7] https://www.environmental-expert.com/companies/ecotech-pty-ltd-10048

[8] Yulan Y. Yuan et al. 2013, Environmental Sustainability

[9] Demirbas 2008, Economic and environmental impacts of the liquid biofuels

[10] K N Balan et al. Analysis of CO2, CO and HC emission reduction in automobiles

[11] https://magnesiaspecialties.com/power-generation/

[12] Carbon Monoxide Poisoning - NHS

[13] https://study.com/academy/lesson/double-displacement-reaction-definition-examples.html

[14] Handbook of Chemistry and Physics (76th ed.). CRC Press. ISBN 0849305969.

[15] https://www.americanelements.com/magnesium-hydroxide-1309-42-8

[16] Essays, UK. (November 2018). Materials Selection For Automotive Exhaust System Engineering

[17] https://en.wikipedia.org/wiki/Muffler

[18] https://www.alibaba.com/showroom/wholesale-magnesium-hydroxide-price.html

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